Progress on critical cell fabrication parameters and designs for advanced lithium-sulfur batteries

Since 1990, commercial lithium-ion batteries have made significant strides, approaching their theoretical performance limits, albeit with escalating costs. To address these challenges, attention has shifted toward lithium-sulfur batteries, which offer higher theoretical energy densities and cost-effectiveness. However, lithium-sulfur cells face challenges such as active-material loss, excessive electrolyte usage, and rapid degradation of lithium-metal anodes. To overcome these issues, research has focused on optimizing cell configurations and fabrication parameters while exploring novel electrolytes and electrode materials. This feature article delves into the intrinsic material challenges and extrinsic engineering issues in current lithium-sulfur research and explores the development of advanced lithium-sulfur cells with crucial progress on high-loading sulfur cathodes, lean-electrolyte cells, and solid-state electrolytes. Moreover, it outlines the fundamental principles, structures, performances, and developmental trajectories indicated in research articles published after 2020, highlighting future research directions aimed at resolving key challenges for the practical application of lithium-sulfur cells.